Ear protection device

ABSTRACT

An apparatus comprising a first curved band portion and a second curved band portion. The first curved band portion has a first end, a second end, an inner curved side and an outer curved side. The first curved band portion defines a passageway between the first end and the second end of the first curved band portion. The passageway has a first opening. The second curved band portion has a first end, a second end, an inner curved side and an outer curved side. A motion-restraint portion is proximate to the first end of the second curved band portion. The first end of the second curved band portion is insertable into the first opening of the passageway of the first curved band portion. The first curved band portion has a range of motion within the passageway of the second curved band portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is continuation of U.S. patentapplication Ser. No. 10/024,523, entitled “Ear Protection Device,” filedDec. 21, 2001, the entire disclosure of which is incorporated herein,which claims priority to and is related to U.S. Provisional ApplicationSerial No. 60/259,114, entitled “Ear Covering,” the entire disclosure ofwhich is incorporated herein by reference.

[0002] The present application is also related to U.S. applicationsSerial Nos. 09/521,241 and 09/978,591, both of which are entitled“Apparatus and Method for Making an Ear Warmer Having Interior Seams,”the entire disclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0003] The invention in general relates to an ear protection device.More specifically, the invention relates to an ear protection devicewith adjustable bands.

[0004] Ear muffs that are worn over the top or around the back of auser's head are generally known. For example, U.S. Pat. No. 1,628,483 toWiegand discloses an ear protector. The ear protector includes a pair ofoval-shaped plates, each plate being formed with an inwardly extendingcontinuous flaring flange. The flange provides a conical profile. Theplates are connected together via slidably connected resilient arms. Theear protector includes a hold fast device or rivet for coupling each ofthe resilient arms to a respective oval plate. The resilient arms eachinclude a band for slidably receiving the other overlapping resilientarm. The bands hold the resilient arms together and allow for thesliding movement between the two resilient arms to allow the earprotector to be adjusted for a specific user. The ear protector can beworn with the resilient arms extending around the back of the head.

[0005] This known ear muff, however, does not effectively maintain itsposition on a user's head. In addition, this ear muff does not allow afabric member to cover entirely the frame structure of the ear muff.

[0006] Thus, a need exists for frames for ear protection devices thatmaintain their position on a user's head. In addition, a need exists fora shell (e.g., made of fabric) that entirely covers theear-protection-device frame.

SUMMARY OF THE INVENTION

[0007] An apparatus comprising a first curved band portion and a secondcurved band portion. The first curved band portion has a first end, asecond end, an inner curved side and an outer curved side. The firstcurved band portion defines a passageway between the first end and thesecond end of the first curved band portion. The passageway has a firstopening. The second curved band portion has a first end, a second end,an inner curved side and an outer curved side. A motion-restraintportion is proximate to the first end of the second curved band portion.The first end of the second curved band portion is insertable into thefirst opening of the passageway of the first curved band portion. Thefirst curved band portion has a range of motion within the passageway ofthe second curved band portion.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 shows a perspective view of an ear protection device,according to an embodiment of the invention.

[0009] FIGS. 2A-2D show a perspective view, a side view, a top view anda front view, respectively, of a first band portion, according to anembodiment of the invention.

[0010] FIGS. 3A-3E show a top perspective view, bottom perspective view,a side view, a top view and a front view, respectively, of a second bandportion, according to an embodiment of the invention.

[0011] FIGS. 4A-4D show a perspective view, a side view, a rear view anda front view, respectively, of two band portions, according to anembodiment of the invention.

[0012]FIG. 5 shows a perspective view of an ear cup portion, accordingto an embodiment of the invention.

[0013]FIG. 6A shows a top view of shell membranes, according to anembodiment of the invention.

[0014]FIG. 6B shows a top view of the shell membranes shown in FIG. 6Awhile assembled into a shell.

[0015]FIG. 7 shows a top view of shell membranes, according to anotherembodiment of the invention.

[0016]FIG. 8 shows a top view of an assembled shell, according toanother embodiment of the invention.

[0017]FIG. 9 shows a top view of shell membranes, according to anotherembodiment of the invention.

[0018]FIG. 10 shows a top view of shell membranes of FIG. 9 partiallysewn during an immediate step of assembling an ear protection device.

[0019]FIG. 11 shows a top view of shell membranes, according to anotherembodiment of the invention.

[0020]FIG. 12 shows a top view of the assembled shell based on the shellmembranes shown in FIG. 1.

[0021]FIG. 13 shows a top view of shell membranes, according anotherembodiment of the invention.

[0022]FIG. 14 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 13.

[0023]FIG. 15 shows a top view of shell membranes, according to anotherembodiment of the invention.

[0024]FIG. 16 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 15.

[0025]FIG. 17 shows a perspective view of two band portions, accordingto an embodiment of the invention.

[0026]FIG. 18 shows an assembly view of a frame, according anotherembodiment of the invention.

[0027]FIG. 19 shows an assembly view of an ear protection device,according to another embodiment of the invention.

[0028]FIG. 20 shows an assembly view of an ear protection device,according to another embodiment of the invention.

[0029]FIG. 21 shows an assembly view of an ear protection device,according to another embodiment of the invention.

[0030]FIG. 22 shows an assembly view of an ear protection device,according to another embodiment of the invention.

DETAILED DESCRIPTION

[0031]FIG. 1 shows a perspective view of an ear protection device,according to an embodiment of the invention. As shown in FIG. 1, the earprotection device 10 includes a head band portion 12 having an innerside 14 and an outer side 16. Ear protection device 10 also includes afirst end portion 18 and a second end portion 20. The first end portion18 and second end portion 20 are connected to respective ear portions22. Each ear portion 22 has an inner side 24 and an outer side 26. Theear protection device 10 is covered in a textile material, such asfleece. Note that the head band portion 12 is covered by excess materialthat gathers.

[0032] FIGS. 2A-2D show a perspective view, a side view, a top view anda front view, respectively, of a first band portion, according to anembodiment of the invention. Band portion 200 includes a first end 34, asecond end 36, an inner side 35 and an outer side 37. Band portion 200includes a raised mounting surface 38 disposed at the outer side 37 andproximate to the first end 34. Band portion 200 also includes amotion-restraint portion 40 disposed at the outer side 37 and proximateto the second end 36 of band portion 200. Although the mounting surface38 and motion-restraint portion 40 are shown as being integrally formedwith the band portion 200, they can be formed separately and attached tothe band portion 200. In an alternative embodiment, the motion-restraintportion can be a detent that is integrally formed with the band portionalong only a single side of the detent while the remaining sides of thedetent are separated (or cut out) from the band portion.

[0033] FIGS. 3A-3E show a top perspective view, bottom perspective view,a side view, a top view and a front view, respectively, of a second bandportion, according to an embodiment of the invention. Band portion 210includes a first end 42, a second end 44, an inner side 45 and an outerside 47. Band portion 210 includes a raised mounting surface 46 disposedat the outer side 47 and proximate to the second end 44. Band portion210 further includes a base member 211, side members 212 and uppermembers (or flanges) 50. The side members 212 are connected along bothsides of the base member 211. The upper members 50 are connected to theside members 212 and protrude over base member 211.

[0034] The base member 211, side members 212 and upper members 50 definea passageway 215 along the band portion 210, lengthwise. In other words,the base member 211, side members 212 and upper members 50 bound achannel on various sides into which the band portion 200 can beslideably engaged. Thus, as the band portion 200 is moved through thepassageway 215, the movement of band portion 200 is limited by the basemember 211, side members 212 and upper members 50. The passageway 215includes an opening 216 into which the band portion 200 can be initiallyinserted.

[0035] FIGS. 4A-4D show a perspective view, a side view, a rear view anda front view, respectively, of two band portions, according to anembodiment of the invention. As shown in FIGS. 4A-4D, band portion 200is inserted into the passageway of band portion 210 through opening 216to provide a band that has an adjustable length. More specifically, themotion-restraint portion 40 of band portion 200 is engagable with theopening 216 of passageway 215 of band portion 210. Once band portion 200has been inserted through opening 216, the motion-restraint portion 40engages the portions of band portion 210 that defines opening 216. Thisallows motion-restraint portion 40 to prevent band portion 200 fromexisting passageway 215 of band portion 210. Consequently, the bandportion 200 has a range of motion within the passageway 215 of bandportion 210 once the band portion 200 has been inserted into passageway215 of band portion 210. This range of motion within the passageway 215is limited on the end with the opening 216 by the engagement ofmotion-restraint portion 40 of band portion 210.

[0036] In an alternative embodiment, the motion-restrain portion canremovably engage the passageway of the other embodiment. For example,the motion-restraint portion can be a detent integrally formed with theband portion along only a single side of the detent while the remainingsides of the detent are separated (or cut out) from the band portion.This allows the band portion to be removably inserted into thepassageway of the other band portion. In other words, the detent can bedepressed to disengage from the opening the passageway thereby allowingthe one band portion to be removed from the other band portion.

[0037] In another alternative embodiment, the motion-restraint portionof one band portion can at least partially engage other openings withinthe passageway of the other band portion. For example, themotion-restraint portion can be a detent and the upper members of theband portion that defines the passageway can extend so that they overlapslightly with the detent. This allows the detent to engage partially theopenings defined by the upper members thereby causing a slighthesitation due to friction when the band portions are moved within therange of motion. Once this partial engagement is overcome, the bandportions can move within the range of motion.

[0038] In yet another alternative embodiment, the upper members thatdefine the passageway of one band portion can further extend so that thedetent of the other band portion removably engages the openings definedby the upper members. In such an embodiment, the two band portions willhave a range of motion that includes one or more positions where thedetent removably engages the openings in the passageway. This removableengagement allows the position of the band portion to be temporarilylocked within the passageway of the other band portion.

[0039] In yet another alternative embodiment, detent-engageable openingsof the passageway of one band portion and the detent of the other bandportion can be located on any of their respective sides. For example,the detent can be located on either side or both sides of the bandportion where the detent-engagable openings of the passageway aredisposed at corresponding locations on the other band portion (i.e., onthe matching side or on both sides of the passageway). Alternatively,the detent can be located on the inner side the band portion where thedetent-engagable openings of the passageway are disposed atcorresponding location(s) on the inner side of the other band portion.In yet another embodiment, multiple detents can be located at differentlocations (i.e., one detent on the outer side and another detent on theinner side) of the band portion where the detent-engagable openings ofthe passageway are disposed at a corresponding locations on the otherband portion.

[0040] Although motion-restraint portion 40 of band portion 200 is shownin FIGS. 2A-2D as a detent, other configurations are possible. Forexample, the motion-restraint portion can be a rivet that is coupled tothe band portion once the band portion is inserted into the passagewayof the other band portion. Such a rivet can be, for example, fixedlyattached or removably attached to the band portion once the band portionis inserted into the passageway of the other band portion.

[0041]FIG. 5 shows a perspective view of an ear cup portion, accordingto an embodiment of the invention. As shown in FIG. 5, ear cup portion54 includes a conical portion 56 having a transition portion 58extending from the side of the conical portion 56. The transitionportion 56 is integrally formed with mount portion 60, which includes ahole 62.

[0042] Two ear cup portions 54 can each be attached to an end of theband portions 200 and 210. In other words, one ear cup portion 54 can beattached to the raised mounting surface 38 of band portion 200 andanother ear cup portion 54 can be attached to the raised mountingsurface 46 of band portion 210. Ear cup portions 54 can be attached toband portions 200 and 210 by a fastener, such as for example, rivet 64.In an alternative embodiment, either the ear cup portion or the raisedmounted surface of the band portions can include an integrally formedrivet for snap-action engagement with a hole in the corresponding matingstructure. Note that band portions 200 and/or 210, and/or ear cupportions 54 collectively are sometimes referred to herein as a “frame”.

[0043]FIG. 6A shows a top view of shell membranes, according to anembodiment of the invention. The shell membranes include outer membrane310, inner membrane 320, and ear membranes 330 and 340. FIG. 6B shows atop view of the shell membranes shown in FIG. 6A while assembled into ashell. As shown in FIG. 6B, the membranes 310, 320, 330 and 340 can bearranged together and then sown with a seam along the perimeter. Theassembled shell 300 includes two openings 350 and 360 into whichportions of the frame can be inserted. For example, the band portion 200with the attached ear cup portion 54 and be inserted into opening 350,and the band portion 210 with the attached ear cup portion 54 can beinserted into opening 360. Additional details and variations of theshell membranes are described in U.S. Pat. No. 5,835,609 to Le Gette etal. entitled “Ear Protection Device;” the disclosure of which isincorporated herein by reference.

[0044] After being inserted into shell 300, the band portions 200 and210 can have an adjustable length to accommodate the use of the earprotection device 10 by users having different size heads or by the sameuser while extending over the top or around the band of that user'shead. In other words, once the band portions 200 and 210 are insertedinto and assembled within the shell 300, the length of the band portions200 and 210 can be adjusted by moving band portion 200 within thepassageway 215 of band portion 210.

[0045] In some embodiments, the band portions can be separated from eachother while disposed within shell 300. For example, where themotion-restraint portion of one band portion is a disengageable detent,the detent can be disengaged from an opening of the passageway of theother band portion, and the band portion can be removed from thepassageway of the other band portion. Then, the band portion with theattached ear cup portion 54 can be removed from shell 300 throughopening 350, and the other band portion with the attached ear cupportion 54 can be removed from shell 300 through opening 360.

[0046] This allows the ear protection device 10 to have interchangeableshells. In other words, different shells can be used to cover the sameframe because the band portions can be separated from each other whiledisposed within one shell and reassembled in another shell. Suchinterchangeable shells, for example, can have different colors or logosfor use with a single frame.

[0047]FIG. 7 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 7, the shell 400 includesouter membrane 410 and inner membrane 420. To assemble an ear protectiondevice using shell 400, the outer membrane 410 and inner membrane 420can be positioned over the other, with the components of the framedisposed between the two membranes 410 and 420, and then the membranes410 and 420 can be sewn along their perimeter.

[0048]FIG. 8 shows a top view of an assembled shell, according toanother embodiment of the invention. As shown in FIG. 8, the shell 500has an inner membrane 510, outer membrane 520 and elastic membranes 530and 540 (shown in phantom). The membranes 510, 520, 530 and 540 are sewnalong the perimeter. The elastic membranes 530 and 540 can be disposedbetween the inner membrane 510 and the outer membrane 520. The elasticmembranes 530 and 540 can form “gathers” in the central portion of theshell 500. The elastic membranes 530 and 540 can gather any additionalmaterial of membranes 510 and 520 when the ear protection device is in aconfiguration other than open. In other words, membranes 510 and 520 canbe fully stretched when the ear protection device is in an openconfiguration and less than fully stretched when the ear protectiondevice is in a closed configuration. Thus, when in the closedconfiguration, the elastic membranes 530 and 540 can gather membranes510 and 520.

[0049]FIG. 9 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown FIG. 9, the shell 600 includesouter 610 membrane and inner membrane 620. Outer membrane 610 includesend portions 611 and 612. Inner membrane 620 includes end portions 621and 622. The end portions 611, 612, 621 and 622 can include, forexample, an elastic material and can be folded over the related frameportion when assembled. The doubled-over arrangement of the end portions611, 612, 621 and 622 can provide cushioning for the frame against thewearer's head. The elastic material can affect the appearance of the earprotection device by pulling the outer membrane 610 and inner membrane620 tight around the perimeter of the ear cup portions of the frame. Inother words, the elastic material can be pulled over the related frameportions so that the outer membrane 610 and inner membrane 620 areremoveably secured to the related frame portions without being sewnalong a seam.

[0050]FIG. 10 shows a top view of shell membranes of FIG. 9 partiallysewn during an immediate step of assembling an ear protection device. Asshown in FIG. 10, the ear protection device can be assembled byinitially sewing a portion of the perimeter 630 and leaving a portion ofthe perimeter 640 and 650 not sewn. Two ear cup portions of the frameeach can be connected to a respective band portion. Each band portionwith its attached ear cup portion of the frame can then be positionedwithin the shell by insertion through the portions 640 and 650. Theinner band portion can then be removably inserted into the passageway ofthe outer band (as described above, for example, in reference to FIGS.4A-4D). In an alternative embodiment, the shell 600 can be turned insideout after the portions of perimeter 630 have been sewn.

[0051]FIG. 11 shows a top view of shell membranes, according to anotherembodiment of the invention. The shell 700 includes outer membrane 710and ear membranes 720 and 730. Outer membrane 710 includes middleportion 715, which is integrally formed with the remaining portions ofouter membrane 710. Ear membranes 720 and 730 each have their ownelastic membrane attached to a portion of the perimeter of therespective ear membrane. In addition, the outer membrane 710 can haveits own elastic membrane attached to the perimeter of the ear portionsof outer membrane 710. Note that although elastic membranes are shown onboth the outer membrane 710 and ear membranes 720 and 730, alternativeembodiments are possible where the elastic membrane is disposed at onlythe outer membrane or only the ear membranes.

[0052] Shell 700 can be assembled by attaching the edge portions 721 and731 of ear membranes 720 and 730, respectively, to portions 711 and 712of outer membrane 710. The middle portion 715 of outer membrane 710 canbe folded over and attached to the portion 716 of the outer membrane710. This is shown in FIG. 12, which shows a top view of the assembledshell based on the shell membranes shown in FIG. 11. The ear membranes720 and 730 optionally can be turned inside out with regards to thecorresponding portions of outer membrane 710. Consequently, theattachment (e.g., a sewn seam) is disposed in the interior formed byouter membrane 710 and ear membranes 720 and 730. The frame can then beinserted into the interior formed by outer membrane 710 and earmembranes 720 and 730. The elastic membranes attached to outer membrane710 and ear membranes 720 and 730 tend to draw the perimeter of theouter membrane 710 and ear membranes 720 and 730 inwardly. Thus, thecorresponding portions of shell 700 close in around the ear cup portionsof the frame. Although not shown explicitly in FIG. 12, the earprotection device will have a curvature corresponding to the shape ofthe frame.

[0053] In an alternative embodiment, the ear membranes need not beattached to portions of the outer membrane. Rather, the middle portionof the outer membrane can be folded over and attached. Then, the framecan be inserted into the interior formed by the outer membrane and themiddle portion of the outer membrane. Finally, the ear membranes can bedisposed and maintained over the ear cup portions of the frame by theelastic membranes attached to the ear membranes and the outer membrane.

[0054]FIG. 13 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 13, shell 800 includes anouter membrane 810 and an inner membrane 820. The lengths of bandportions 811 and 821 of outer membrane 810 and inner membrane 820,respectively, are greater than the corresponding portion of the frame.This extra length allows the shell 800 to gather with extra materialabout the portions 811 and 821.

[0055] In addition, the ear portions 822 and 823 of inner membrane 820can have lengths along direction 824 greater than the corresponding earcup portions of the frame. An elastic membrane, while stretched, can beattached to the perimeter of ear portions 822 and 823. This extra sizeof ear portions 822 and 823 along direction 824 and the stretchedelastic membrane allows the ear portions 822 and 823 to draw inwardly.

[0056]FIG. 14 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 13. As shown in FIG. 14, the outer membrane 810and inner membrane 820 can be attached together at the positions 830 and831. The frame can be inserted into an interior defined between theouter membrane 810 and inner membrane 820. The inward draw of theelastic membrane of ear portions 822 and 823 allows these to gatherabout the ear cup portions of the frame when inserted into an interiorformed by inner membrane 810 and outer membrane 820.

[0057]FIG. 15 shows a top view of shell membranes, according to anotherembodiment of the invention. As shown in FIG. 15, shell 900 includes earmembranes 910, 920, 930 and 940, and middle membrane 950. The middlemembrane 950 can be a knit tube or a membrane folded over to form a tubeshape. Ear membranes 910 and 930 can be attached together, and earmembranes 920 and 940 can be attached together. Once attached, forexample, by sewing, these attached ear membranes can be attached tomiddle membrane 950. Alternatively, these attached ear membranes can beturned inside out and then attached to middle membrane 950. In yetanother alternative, the attached ear membranes can include additionelastic membranes as discussed above in reference to, for example, FIG.11. FIG. 16 shows a top view of an assembled shell based on the shellmembranes shown in FIG. 15.

[0058]FIG. 17 shows a perspective view of two band portions, accordingto an embodiment of the invention. As shown in FIG. 17, band portion1000 includes a first end 1001, a second end 1002, an inner side 1003and an outer side 1004. The first end 1001 of band portion 1000 includesan opening. The second end 1002 of band portion 1000 includes a mountingportion 1005. Band portion 1000 has a base member 1006, side members1007 and upper member 1008. Base member 1006, side members 1007 andupper members 1008 define a passageway along the band portion 1000,lengthwise. The passageway includes openings along the base member 1006,side members 1007 and upper member 1008.

[0059] Band portion 1010 includes a first end 1011 and a second end1012. Band portion 1010 also includes a motion-restraint portion 1013(shown as a detent in phantom) on the outer side of the first end 1011of band portion 1010. Band portion 1010 also includes a mounting portion1015 on the second end 1012.

[0060] Band portion 1010 can be slidably engaged into the passageway ofband portion 1000. The motion-restraint portion 1013 of band portion1010 can be engaged through opening 1009 of the passageway. Note thatthe band portion 1000 can easily flex either inwardly or outwardlybecause both the base member 1006 and the upper member 1008 haveopenings. In other words, as the band portions 1000 and 1010 areadjusted (e.g., while band portion 1010 is slidably engaged within thepasssageway of band portion 1000), these band portions can easily flexinwardly or outwardly due to the openings in the base member 1006 andthe upper member 1008 of band portion 1000. In an alternativeembodiment, the motion-restraint portion can be integrally formed withthe band portion along only a single side of the detent while theremaining sides of the detent are separated (or cut out) from the bandportion. Such an embodiment allows the one band portion to be removablyand slideably engaged into the passageway of the other band portion.

[0061] In another alternative embodiment, the motion-restraint portioncan be a disengageable detent. The detent can be removably engageablewith any of the openings of the passageway of the other band portion.Thus, the detent can be removably engageable into the openings of theupper member of the other band portion. This allows the band portions tobe temporarily locked in multiple possible positions within the range ofmotion for the one band portion within the passageway of the other bandportion. Note also that although the detent can be on the outer side ofthe band portion thereby corresponding to detent-engageable openings onthe upper member of the other band portion, other arrangements arepossible. For example, a detent can be located on any of the four sidesof the band portion (either alone or in combination with detents onother sides) because the band portion includes openings on its foursides: the base member, the side members and the upper member.

[0062]FIG. 18 shows an assembly view of a frame, according anotherembodiment of the invention. As shown FIG. 18, the frame 1100 includes aband 1110 and ear cup portion 1120. Note that although a single ear cupportion 1120 is shown in FIG. 18, the frame 1100 includes a second earcup portion that is attached to the band 1110 on the side opposite fromear cup portion 1120.

[0063] Ear cup portion 1120 includes attachment portions 1121 and 1122,ear cup 1124 and cushion insert 1126. Cushion insert 1126 can be madeof, for example, urethane foam. The cushion insert 1126 can be attachedto ear cup 1124 by, for example, glue. Cushion insert 1126 can providecushioning between the ear cup 1124 and the user's head.

[0064] Attachment portions 1121 and 1122 of ear cup portion 1120 areproximal and distal, respectively, to the band 1110. The end of the band1110 can be inserted into the attachment portions 1121 and 1122 so thatband 1110 is attached to ear cup portion 1120 by, for example, afriction fit. Such a friction fit allows the band 1110 to be removedfrom and reattached to ear cup portion.

[0065]FIG. 19 shows an assembly view of an ear protection device,according to another embodiment of the invention. As shown in FIG. 19,ear protection device 1200 includes a band 1210, a band membrane 1220,ear cup portions 1230 and 1240 and ear cup membranes 1250 and 1260. Theband membrane 1220 can be, for example, elastic piping with binding onthe upper and lower side of the piping that allows the band membrane1220 to fit over the band 1210. The band 1210 can be, for example, anadjustable spring-like band having two portions. Each end of the band1210 can have a protrusion-locking portion 1211 and 1212. Morespecifically, protrusion-locking portions 1211 and 1212 can have abarbed shape.

[0066] Ear cup portions 1230 and 1240 can be made of, for example, asemi-rigid material such as foam. Protrusion-locking portions 1211 and1212 can be inserted into ear cup portions 1230 and 1240, respectively.Note that protrusion-locking portion 1211 is shown in phantom within earcup portion 1230 for illustrative purposes. The barbed shape ofprotrusion-locking portions 1211 and 1212 allows the protrusion-lockingportions 1211 and 1212 to be retained within the ear cup portions 1230and 1240. In one embodiment, protrusion-locking portions 1211 and 1212can be inserted into ear cup portions 1230 and 1240, respectively, withglue to provide additional retention.

[0067] The ear cup membranes 1250 and 1260 each can be made of, forexample, a fabric material on both sides thereby forming an interiorinto which ear cup portions 1230 and 1240, respectively, can beinserted. In other words, ear cup membranes 1250 and 1260 can be coversinto which ear cup portions 1230 and 1240, respectively, can beinserted.

[0068]FIG. 20 shows an assembly view of an ear protection device,according to another embodiment of the invention. As shown in FIG. 20,ear protection device 1300 includes a band 1310, a band membrane 1320,ear cup portions 1330 and 1340 and ear cup membranes 1350 and 1360. Theband membrane 1320 can be, for example, elastic piping with a binding onthe upper and lower side of the piping that allows the band membrane1320 to fit over the band 1310. The band 1310 can be, for example, anadjustable spring-like band having two portions. Each end of the band1310 can be coupled to a protrusion-locking portion 1311 and 1312. Morespecifically, protrusion-locking portions 1311 and 1312 can have a ballconnector configured to lock into a ball-joint connection with the earcup portions 1330 and 1340. The protrusion-locking portions 1311 and1312 can have a post configuration that can friction fit into the clipends of the band 1310. Such a post-clip configuration allows the ear cupportions 1330 and 1340 to rotate about the ends of band 1310 when in aclosed configuration.

[0069] Ear cup portions 1330 and 1340 can be made of, for example,molded plastic. Ear cup portions 1330 and 1340 each can include a jointportion of a ball-joint connection that is configured to connect withprotrusion-locking portions 1311 and 1312. The joint portion of each earcup portions 1330 and 1340 can be disposed at an end proximal toprotrusion-locking portions 1311 and 1312. Thus, protrusion-lockingportions 1311 and 1312 can be removably connected to ear cup portions1330 and 1340, respectively.

[0070] The ear cup membranes 1350 and 1360 each can be made of, forexample, a fabric material on both sides thereby forming an interiorinto which ear cup portions 1330 and 1340, respectively, can beinserted. In other words, ear cup membranes 1350 and 1360 can be coversinto which ear cup portions 1330 and 1340, respectively, can beinserted.

[0071]FIG. 21 shows an assembly view of an ear protection device,according to another embodiment of the invention. As shown in FIG. 21,ear protection device 1400 includes a band 1410, a band membrane 1420,ear cup portions 1430 and 1440 and ear cup membrane 1450. The bandmembrane 1420 can be, for example, elastic piping with a binding on theupper and lower side of the piping that allows the band membrane 1420 tofit over the band 1410. The band 1410 can be, for example, an adjustablespring-like band having two portions. Each end of the band 1410 can becoupled to a protrusion-locking portion 1411 and 1412. Morespecifically, protrusion-locking portions 1411 and 1412 each can have aclamp connector configured to lock by a friction fit into a post withinthe ear cup portions 1430 and 1440. Such a hinge-post configurationallows the ear cup portions 1430 and 1440 to rotate about the ends ofband 1410 when in a closed configuration.

[0072] Ear cup portions 1430 and 1440 can be made of, for example,molded plastic. Protrusion-locking portions 1411 and 1412 can beremovably connected to ear cup portions 1430 and 1440, respectively.

[0073] The ear cup membrane 1450 can be made of, for example, a fabricmaterial on both sides thereby forming an interior into which ear cupportion 1430 can be inserted. In other words, ear cup membrane 1450 canbe a cover into which ear cup portion 1430 can be inserted. Note thatalthough not shown in FIG. 21, an additional ear cup membrane can beused to cover ear cup portion 1440.

[0074]FIG. 22 shows an assembly view of an ear protection device,according to another embodiment of the invention. As shown in FIG. 22,ear protection device 1500 includes a band 1510, a band membrane 1520,ear cup portions 1530 and 1540 and ear cup membranes 1550 and 1560. Theband membrane 1520 can be, for example, a cloth tube into which band1510 can be inserted. The band membrane 1520 can include ends 1521 and1522 that can be made of, for example, lycra or similar elasticmaterial. The band 1510 can be, for example, an adjustable spring-likeband having two portions. One end of the band 1510 includes aprotrusion-locking portion 1511 and the other end of band 1510 includesa protrusion-locking portion 1512. More specifically, protrusion-lockingportions 1511 and 1512 each can have a knob configured to lock by a snapfit into a hole in the ear cup portions 1530 and 1540. Such a snap-fitconfiguration allows the ear cup portions 1530 and 1540 to rotate aboutthe ends of band 1510 when in a closed configuration.

[0075] Ear cup portions 1530 and 1540 can be made of, for example,molded plastic. The ear cup membranes 1550 and 1560 each can be made of,for example, a fabric material on both sides thereby forming an interiorinto which ear cup portions 1530 and 1540 can be inserted. In otherwords, ear cup membranes 1550 and 1560 can be a cover into which ear cupportions 1530 and 1540 can be inserted.

[0076] While various embodiments of the invention have been describedabove, it should be understood that they have been presented by way ofexample only, and not limitation. Thus, the breadth and scope of thepresent invention should not be limited by any of the above-describedembodiments, but should be defined only in accordance with the followingclaims and their equivalents.

[0077] The previous description of the embodiments is provided to enableany person skilled in the art to make or use the invention. While theinvention has been particularly shown and described with reference toembodiments thereof, it will be understood by those skilled in the artthat various changes in form and details may be made therein withoutdeparting from the spirit and scope of the invention.

[0078] For example, although certain frame embodiments are described asbeing inserted into certain shell embodiments, other arrangements arepossible. Any of the frame embodiments described above can be insertedinto other shell configurations disclosed in, for example, U.S. Pat. No.5,835,609, and pending U.S. applications Ser. Nos. 09/521,241 and09/978,591, both of which are entitled “Apparatus and Method for Makingan Ear Warmer Having Interior Seams.” In addition, any of the shellembodiments described above can be used in combination with the framesdescribed in U.S. Pat. No. 5,835,609. The entire disclosures of U.S.Pat. No. 5,835,609 and pending U.S. applications Ser. Nos. 09/521,241and 09/978,591, are incorporated herein by reference.

What is claimed is:
 1. An apparatus, comprising: a band having a firstend and a second end; a first ear cup portion, said first ear cupportion being coupled proximate to said first end of said band, saidfirst ear cup portion including a first attachment portion and a secondattachment portion, said first end of said band being configured toengage said first attachment portion and said second attachment portionon said first ear cup portion at separate longitudinal positions alongsaid first end of said band; and a second ear cup portion, said secondear cup portion being coupled proximate to said second end of said band,said second ear cup portion including its own first attachment portionand second attachment portion, said second end of said band beingconfigured to engage said first attachment portion and said secondattachment portion on said second ear cup portion at separatelongitudinal positions along said second end of said band.
 2. Theapparatus of claim 1, wherein said first end of said band is insertableinto said first attachment portion and said second attachment portion onsaid first ear cup portion, said second end of said band beinginsertable into said first attachment portion and said second attachmentportion on said second ear cup portion.
 3. The apparatus of claim 1,wherein said first ear cup portion is pivotally coupled to said firstend of said band, said second ear cup portion being pivotally coupled tosaid second end of said band.
 4. The apparatus of claim 1, wherein saidfirst ear cup portion includes an ear cup and a cushion insert, saidfirst attachment portion and said second attachment portion of saidfirst ear cup portion being coupled to said ear cup.
 5. The apparatus ofclaim 4, wherein said first attachment portion of said first ear cupportion is located on a proximal end of said ear cup relative to saidband, said second attachment portion of said first ear cup portion beinglocated on a distal end of said ear cup relative to said band.
 6. An earprotection device comprising: a band, said band including a first end, asecond end, a first locking protrusion located proximate to said firstend, and a second locking protrusion located proximate to said secondend; a band membrane, said band membrane covering a portion of saidband; a first ear cup portion, said first ear cup portion beingconfigured to receive said first locking protrusion; and a second earcup portion, said second ear cup portion being configured to receivesaid second locking protrusion.
 7. The ear protection device of claim 6,wherein each of said first locking protrusion and said second lockingprotrusion includes a barbed shape.
 8. The ear protection device ofclaim 6, wherein said first locking protrusion is configured to beinserted into and retained within said first ear cup portion.
 9. The earprotection device of claim 6, wherein said first ear cup portion isformed of a semi-rigid material, said first locking protrusion beingconfigured to be inserted into and retained within said first ear cupportion.
 10. The ear protection device of claim 9, wherein saidsemi-rigid material is foam.
 11. The ear protection device of claim 6,further comprising: a first ear cup membrane, said first ear cupmembrane defining an interior configured to receive said first ear cupportion; and a second ear cup membrane, said second ear cup membranedefining its own interior configured to receive said second ear cupportion.
 12. An adjustable band comprising: a first band portion, saidfirst band portion including a first end, a second end, a base member,an upper member, a first side member and a second side member, each ofsaid first side member and said second side member being coupled to saidbase member and said upper member, said base member, said upper member,said first side member and said second side member collectively definingtherebetween a passageway along said first band portion, said basemember defining a base member opening in communication with saidpassageway, said upper member defining an upper member opening incommunication with said passageway, and said first side member definingan opening of the first side member in communication with saidpassageway; and a second band portion, said second band portion beingconfigured to be inserted into said passageway of said first bandportion, said second band portion including a motion-restraint portioncoupled thereto, said motion-restraint portion being disposed so thatsaid motion restraint portion engages one of said base member, saidupper member, said first side member and said second side member. 13.The adjustable band of claim 12, wherein said upper member opening isformed with said first side member opening.
 14. The adjustable band ofclaim 12, wherein said opening of said first side member is a firstopening, said first side member including a second opening spaced apartfrom said first opening, said first opening being formed with said uppermember opening, said second opening being formed with said base memberopening.
 15. The adjustable band of claim 12, wherein said second sidemember defines its own opening, said second side member opening beingaligned with said first side member opening.
 16. An adjustable bandcomprising: a first band portion, said first band portion includingmeans for defining a passageway, said means for defining a passagewayincluding means for facilitating flexing of said first band portion; anda second band portion, said second band portion being configured to beinserted into said passageway, said second band portion including meansfor retaining said second band portion in said passageway.
 17. Theadjustable band of claim 16, said means for defining a passagewayincluding a base member, an upper member, a first side member and asecond side member, said means for facilitating flexing including anopening formed in said upper member and an opening formed in said firstside member.
 18. An adjustable band comprising: a first band portion,said first band portion including a first end, a second end, a portiondefining an opening proximate to said first end, a base member extendingbetween said first end and said second end, a plurality of side memberscoupled to said base member, and a plurality of upper members, eachupper member from said plurality of upper members being coupled to aunique side member from said plurality of side members, said basemember, said plurality of side members and said plurality of uppermembers collectively defining therebetween a passageway; and a secondband portion, said second band portion being configured to be insertedinto said passageway, said second band portion including amotion-restraint portion that is configured to engage said portion ofsaid first band portion defining the opening to couple said second bandportion and said first band portion.
 19. The adjustable band of claim18, wherein said plurality of upper members being configured to engagesaid motion-restraint portion of said second band portion to retain saidsecond band portion in a plurality of positions with respect to saidfirst band portion.
 20. The adjustable band of claim 18, wherein saidbase member includes a first side and a second side, said plurality ofside members including a first side member and a second side membercoupled proximate to said base member first side, and a third sidemember and a fourth side member coupled proximate to said base membersecond side.
 21. The adjustable band of claim 20, wherein said pluralityof upper members includes a first upper member coupled to said firstside member, a second upper member coupled to said second side member, athird upper member coupled to said third side member and a fourth uppermember coupled to said fourth side member.
 22. The adjustable band ofclaim 21, wherein said base member includes a longitudinal axis, saidfirst side member being substantially aligned with said third sidemember, said second side member being substantially aligned with saidfourth side member, said first upper member being offset from said thirdupper member along said longitudinal axis, and said second upper memberbeing offset from said fourth upper member along said longitudinal axis.23. An ear warmer shell, comprising: an outer membrane, said outermembrane including a first end portion and a second end portion, each ofsaid first end portion and said second end portion including elasticmaterial coupled thereto; and an inner membrane, said inner membraneincluding its own first end portion and second end portion, each of saidfirst end portion and said second end portion of said inner membraneincluding elastic material coupled thereto, said inner membrane beingcoupled to said outer membrane.
 24. An ear warmer shell, comprising: anouter membrane, said outer membrane including a first ear portion, asecond ear portion and a middle portion disposed between said first earportion and said second ear portion, said outer membrane including aperimeter and an elastic membrane coupled proximate to said perimeter;and an inner membrane, said inner membrane including a first earmembrane, said first ear membrane being coupled to said first earportion.
 25. The ear warmer shell of claim 24, wherein said elasticmembrane is disposed proximate to said middle portion.
 26. The earwarmer shell of claim 24, further comprising: a second ear membrane,said second ear membrane being coupled to said second ear portion ofsaid outer membrane.
 27. The ear warmer shell of claim 26, wherein saidfirst ear membrane includes a perimeter and an elastic membrane coupledto a portion of said perimeter, and said second ear membrane includingits own perimeter and elastic membrane coupled to a portion of its ownperimeter.
 28. The ear warmer shell of claim 24, wherein each of saidfirst ear portion and said second ear portion includes a perimeter, saidouter membrane including a first elastic membrane coupled to saidperimeter of said first ear portion and a second elastic membranecoupled to said perimeter of said second ear portion.
 29. A method ofassembling an ear warmer frame, the frame including a band, the bandhaving a first end and a second end, the band including a firstprotrusion locking portion coupled to the band first end and a secondprotrusion locking portion coupled to the band second end, the methodcomprising: coupling the first protrusion locking portion to a first earcup portion, the first protrusion locking portion being coupled to alocation proximate the center of the first ear cup portion, the firstear cup portion being configured to rotate about the first protrusionlocking portion; and coupling the second protrusion locking portion to asecond ear cup portion, the second protrusion locking portion beingcoupled to a location proximate the center of the second ear cupportion, the second ear cup portion being configured to rotate about thesecond protrusion locking portion.
 30. The method of claim 29, whereinthe first ear cup portion includes a post, the first protrusion lockingportion including a connector configured to be coupled to the post, saidcoupling the first protrusion locking portion including coupling theconnector to the post.
 31. The method of claim 29, wherein the first earcup portion includes a portion defining an opening, the first protrusionlocking portion including a knob, said coupling the first protrusionlocking portion including engaging the opening with the knob.
 32. Themethod of claim 29, wherein the first protrusion locking portion isremovably coupled to the band first end.